Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 605

ENGINE ELECTRICAL 6D – 27

DISASSEMBLY

Disassembly Steps

J

1. Lead wire

J

14.

Armature

2. Bolt

15.

Screw

J

3. Magnetic switch assembly

J

16.

Bearing retainer

4. Torsion spring

J

17.

Pinion assembly

5. Plunger

18.

Pinion stopper clip

6. Adjusting shims

19.

Pinion stopper

7. Magnetic switch

20.

Return spring

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8. Screw

21.

Pinion

shaft

J

9. Through bolt

22.

Clutch

J

10. Rear cover

J

23.

Dust cover

J

11. Motor assembly

J

24.

Shift lever

J

12. Brush holder

J

25.

Gear case

J

13. Yoke

6D – 28 ENGINE ELECTRICAL

Important Operations

1. Lead

Wire

Disconnect the lead wire at the magnetic switch.

3. Magnetic

Switch

Assembly

Remove the magnetic switch bolts, then remove the
switch from the shift lever.

Remove the torsion spring from the magnetic switch.

8. Screw
9. Through

Bolt

10. Rear Cover

Remove the through bolts, then remove the rear cover.

11. Motor Assembly

Remove the four brushes from the brush holders.

ENGINE ELECTRICAL 6D – 29

Remove the yoke along with the armature and the brush
holder from the gear case.
Remove the brushes and commutator carefully so as not
to allow them in contact with the adjacent parts.

12. Brush Holder
13. Yoke
14. Armature

Remove the brush holder and pull out the armature
assembly free from the yoke.

16. Bearing Retainer
17. Pinion Assembly
23. Dust Cover
24. Shift Lever
25. Gear Case

1. Remove the bearing retainer.
2. Remove the pinion from the gear case.

3. Use a screwdriver to remove the stopper clip. Then

disassemble the pinion assembly.

6D – 30 ENGINE ELECTRICAL

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.

ARMATURE

1. Measure the commutator run-out.

Replace the commutator if the measured run-out
exceeds the specified limit.

Commutator Run-Out

mm (in)

Standard Limit

0.02 (0.001)

0.05 (0.002)

2. Check the commutator mica segments for excessive

wear.

3. Measure the mica segment depth.
Mica Segment Depth

mm (in)

Standard Limit

0.7 – 0.9 (0.028 – 0.035)

0.2 (0.01)

If the mica segment depth is less than the standard but
more than the limit, the commutator may be reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.

4. Measure the commutator outside diameter.
Commutator Outside Diameter

mm (in)

Standard Limit

35 (1.4)

34 (1.3)

If the measured outside diameter is less than the specified
limit, the commutator must be replaced.